Micro- and nano-scale structures - QMT mag · CAM, has adopted the five ... Wipro Technologies....
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www.qmtmag.com september 2009 The development of a micro standards infrastructure is critical for manufacturers to interchange parts, packaging and designs - NPL - see page 28 Metrology challenge Micro- and nano-scale structures Metrology challenge Micro- and nano-scale structures
Transcript of Micro- and nano-scale structures - QMT mag · CAM, has adopted the five ... Wipro Technologies....
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september 2009
The development of a micro standards infrastructure is critical for manufacturers to
interchange parts, packaging and designs - NPL - see page 28
Metrology challengeMicro- and nano-scale structuresMetrology challengeMicro- and nano-scale structures
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3QMT September 2009www.qmtmag.com
CONTENTS
September 2009News and comment 4
Perceived quality 6Quality is in the eye of the beholder - manufacturing vari-ation simulation and visualization software help GMOpel/Vauxhall's Insignia win Car of the Year 2009 award
Data management 12Measurement data available anytime, anywhere at theVW engine works in Chemnitz, Germany.
Turbo charged inspection 13Leader in five-axis turbomachinery production, TURBO-CAM, has adopted the five-axis Renishaw inspection sys-tem to achieve faster throughput, big programmingreductions and greater CMM utilization.
CMMs 17
Nano and micrometrology 21
Optimal quality at BMW 24BMW Group has made an euro 170 million investment inthe future with its advanced Aerodynamic Test Centre inMunich.
Testing quality in India 26Electronic product testing and quality - the key to elec-tronic product development in India. By Prasad Bhatt –vice president, Product Engineering Services, WiproTechnologies.
Metrology for nanotechnology 28The development of a micro standards infrastructure is acritical for manufacturers to interchange parts, packagingand designs. By Richard Leach, EngineeringMeasurement Division, National Physical Laboratory.
Straining to get it right 30The new standard ISO 6892-1 : 2009 will improve thereproducibility of test results obtained from a tensile teston metal. Closed loop strain control systems of testingmachines will deliver results with a higher degree of con-fidence.
Environmental testing 33
Materials Testing 2009 preview 34Materials Testing 2009, in Blackpool, is the the industry'spremier event for NDT technology with a comprehensiveexhibition and conference organised by the BritishInstitute of NDT.
NDT & NDI 37
Testing products 38
Education & Training 39
Editor - Publisher: Brendan CoyneEmail: [email protected]: 00 44 1580 715152
Media Director - Publisher:Dawn WisbeyEmail: [email protected]: 00 44 208 2897011Mob: 0044 797 4640371
Website: www.qmtmag.com
Quality Manufacturing Today , pub-lished eight times a year, is a print andon-line magazine for the quality,measurement and test industry pro-moting improvements in manufactur-ing processes and products throughquality control and quality manage-ment - from shopfloor to line andenterprise management.
Quality Manufacturing Today is pub-lished by Cranbrook Media Ltd.Registered company No. 06048241Registered office: The Coach House,Angley Road, Cranbrook, Kent, TN17 2LE, UK.
Printers: Premier Press, Southend© Cranbrook Media Ltd.
Product and feature articleenquiriesLog on to www.qmtmag.com fordirect links to companies andproducts featured in this issue.
FREE SUBSCRIPTION - UKand Europe
Register online atwww.qmtmag.com
TESTTTING
SUPPLEMENT
QMT_Sep09.pdf_1 24/8/09 13:59 Page 3
National FreeformCentre launch The NPL is setting up a Centrefor Freeform Measurement,together with a special inter-est network for freeformmetrology. Launching at theNPL, Teddington, on 1stOctober, this industriallyfocused centre will providehigh precision measuringfacilities, such as laser scan-ners, white light fringe projec-tors and other coordinatemeasuring systems. It will alsoprovide traceability routes viacomplex reference artefactsand support for a range ofdiverse measuring techniquesand associated point clouddata handling processes.
Confirmed speakers at thisfree one-day launch include:
• Chris Simmons – Rolls-Royce plc
• Dr Michael McCarthy –National Physical Laboratory
• Andrew Brownhill – UKAtomic Energy Authority
• Annemarie La Pensée –National Museums Liverpool
• Dr Lifong Lou – Instituteof Dentistry at Barts and the
London School of Medicineand Dentistry
• Andy Robinson –National Physical Laboratory
• David Bambrough –Nissan Motor Manufacturing(UK) Ltd
The event includes a tour ofthe Free Form Centre.
Enquires - contact:Hannah Carter [email protected] ortelephone 020 8943 6612Technical enquires: contact:Dr Michael McCarthy [email protected] telephone 020 8943 6655
www.npl.co.uk
X-ray CT imaging facilityat Manchester universityDinosaur experts will rubshoulders with aircraft design-ers at a new x-ray imagingfacility at the University ofManchester, which was offi-cially opened on June 8th.
The Henry Moseley X-rayImaging Facility recently tookdelivery of a powerful andhighly accurate custom Metris
320kV Micro-CT system.Located at the MaterialsScience Centre at theUniversity of Manchester, theHenry Moseley X-ray ImagingFacility houses a suite of fivecomputed tomography (CT)systems.
Researchers will be able toexamine a wide range ofmaterials, from micron-sizedbiological samples to heavyengineering components.Biological events, degradation
Norbar wins Couttsprize for familybusinessNorbar Torque Tools,fromBanbury, has been named BestUK Family Business in the £5-25m turnover category of theCoutts Prize for Family Business2008/9. They were in competi-tion with knitwear manufactur-er John Smedley and specialist
pharmaceutical and medicalsupplies distributor Durbin Plcat the national finals held atthe Coutts headquarters on theStrand in London.
Established in 1942, Norbaras a third generation familybusiness became the first com-pany in Britain to commerciallymanufacture a torque wrench.Norbar now employs 200 peo-ple in Banbury, with a further90 staff within its sales compa-nies overseas.
The Coutts Prize recognisesfirms in three categories (£1m-5m, £5m-£25m, £25m+) thatdemonstrate a combination ofhigh standards of family gov-ernance and corporate gover-nance, a competitive marketposition, consistent financialgrowth, and a track record ofcharitable giving or involve-ment in local community.
www.norbar.comwww.coutts.com
PeopleJames Barnes has beenappointed as exclusive salesrepresentative for VerisufSoftware for the UK andIreland.
Editor’s commentFirst impressions count -whether its a job interview,house or car purchase.Those first few seconds veryoften determine the fate ofan individual and the suc-cess (or failure) of a transac-tion. It’s a gut feelingapproach to life which issubsequently confirmed byfacts and figures. We lookfor precisely those facts andfigures which serve to rein-force our decision, validateour emotional judgement.
When it comes to pur-chasing a product, such as acar, this emotional judge-ment is critical. One of thethings we look for is beauty -how good does the car look,how much will we enjoythe look and feel of sitting ina prized possession of, say,an Aston Martin? or a BMW?Glossy magazines havepages of very expensivelyproduced on-location shots,TV adverts spare no expenseand car company literatureooze quality. Perception ofbeauty is the key to brandidentity. Visibly high qualityis an important differentiat-ing factor because it is usedby potential customers todecide which products andbrands they will consider forpurchase. But beauty, as weall know, is in the eye of thebeholder - ie. it is a subjec-tive quality and subjectivequalities are harder to quan-
tify than objective qualitiesor attributes, such as dimen-sion or colour.
So it is interesting to read,on page 6 of this month’sQMT, how car manufactur-er, GM Europe, made use ofadvanced simulation andvisualization software toachieve success for itsInsignia model. Right fromthe design stage, thisapproach enabled the vari-ous design, engineering andmanufacturing disciplinesinvolved in the insignia proj-ect to understand the manu-facturing constraints and toagree on gap and flush con-ditions and manufacturingtolerances as early as possi-ble in the overall design anddevelopment process. Thismade it possible to achievethe highest possible per-ceived quality in the finalvehicle without negativelyimpacting its developmentand manufacturing costs.
Enjoy your read.
Brendan CoyneEditor, QMT
NEWS
www.qmtmag.com QMT September 20094
NEWS
Continued on page 5
IN BRIEF
Left to right in photo: Philip Brodey, Catherine
Brodey, Craig Brodey(Chairman), Neill Brodey
and John Brodey
QMT_Sep09.pdf_1 24/8/09 13:59 Page 4
processes such as corrosion,or crushing of materials canbe monitored in a non-inva-sive way. Imaging equipmentis supported by a suite ofpowerful workstations for theoff-line reconstruction andvisualization of data.
Prof Phil Withers, founderof the new facility said: “Froma series of 2D x-ray images wecan construct 3D ‘pictures’.This facility enables us tostudy how things evolve overtime, either naturally or undera range of loads, temperaturesor other stimuli. It is bringingtogether scientists and engi-neers from many disciplinesto see things behave at a levelof detail not previously possi-ble.”
www.metris.com
Mantech to representWerth in UKMantech Sales Ltd has wonthe contract to distributeWerth Messtechnik GmbH’sdimensional measurementmachines in the UK. Mantechsay they have already securedorders of 1.4 million euros,which includes the sale of aWerth Tomoscope CT scan-ner.
Email; [email protected]
Advanced manufacturingsupport package for UKlaunched.“The UK not a post industrialsociety,” said Lord Mandelsonat the launch of a £151 mil-lion package of support foradvanced manufacturingannounced on July 28th. Thesecretary of state for Business,Innovation and Skills, BIS,pointed out that the UK had a(fractionally) larger manufac-turing sector than that ofFrance, commonly regardedas a strong manufacturingnation and is ranked sixth inthe world by measured out-put. Lord Mandelson said theUK is particularly well placedas a leading exporter of hi-tech goods with 25% of
exports defined as high-techcompared to 22% for theUSA, 15% for France and 115for Germany.
Building on the 2008Government’s Manufacturingstrategy and the NewIndustry, New Jobs strategy ofApril 2009, the AdvanceManufacturing initiativeincludes £45 million of fund-ing to Rolls-Royce, part of a£300 million investment bythe the global company. Fournew advanced manufacturingfacilities are to be built in theUK – three in aerospace andone civil nuclear - creatingand sustaining around 800jobs.
Additionally , there is a pro-vision of £45 million from thelow carbon element of theStrategic Investment Fund tosupport research and technol-ogy critical to the develop-ment of low carbon aircraftengine technology. This willbe led by Rolls-Royce whowill invest a further £45 mil-lion
Another key element of thesupport package announcedis a £40+ million investmentin SAMULET Research andTechnology programme – acollaborative aerospace proj-ect focussing on productivityand environmental improve-ments – with £28.5 millionfrom the Technology StrategyBoard, £11.5 million from theEngineering and PhysicalSciences Research Council,and further support under dis-cussion with regional bodies;
Other elements include: - £12 million expansion of
the Printable ElectronicsCentre in Sedgefield whichfocuses on display technolo-gy, creating up to 1,500 jobsby 2014;
- The Technology StrategyBoard will invest a further £5million in collaborative R&Dprojects as part of its HighValue Manufacturing compe-tition, in addition to the £24million invested earlier thisyear.
NEWS
QMT September 2009 5
October 1National Free Form CentrelaunchNPL. Teddington, UK
www.npl.co.uk
September 15 -17thMaterial Testing 2009Norbreck Castle Hotel,Blackpool UK
www.bindt.org
October 8 -10thEMOMilan, Italy
www.emo-milan.com
October 20 -21stMM Live 2009.ExhibitionRicoh Arena, Coventry,UK
www.micro-show.com
October 26 - 29thEuropean Business ExcellenceSummitSheraton Airport Hotel,Brussels, Belgium
www.businessexcellencesum-mit.com
November 3 - 4th Large Volume MetrologyConference & Exhibition 2009Chester Racecourse, UK
www.lvmc.org.uk
November 10 - 11thAero Engineering 09Manchester CentralConvention ComplexManchester, UK
www.aeroconf.com
December 3-6thEuromold 2009Frankfurt, Germany
www.euromold.com
2010June 7 -11thMACH 2010NEC Birmingham UK
www.mach2010.com
May 4 -7th24th CONTROL internationaltrade fair for quality assuranceStuttgart, Germany
www.control-messe.com
EVENTS £1.4 million investmentin optical metrology Loughborough-based PhaseVision has secured funding ofover £1.4M for investment in3D optical metrology basedon structured light. The fund-ing was lead by OctopusVentures, with the LachesisFund (and others) also partici-pating. Assistance was pro-vided by Connect Midlands.
The company’s productsare 3D measurement systemsusing a non-contact struc-tured lighting technique, orig-inally developed atLoughborough University.“Our systems provide data tocontrol manufacturingprocesses accurately and rap-idly, saving money, energyand scrap,” explains CEORalph Weir, a veteran of sev-eral VC-backed start-ups.Weir continues; “We’ve effec-tively mastered the use ofbroadband light for measure-ment, which brings the samegains that broadband broughtto the internet. With this well-proven technology at ourcore, we now also have theinvestment to build our pro-duction and sales organisa-tions to create a real worldleader.
Phase Vision’s product iscurrently in beta trials at sev-eral sites in the UK, and willbe more widely available laterin the year.
www.phasevision.com
QMT_Sep09.pdf_1 24/8/09 13:59 Page 5
The dimensional management team at GMEurope’s International TechnicalDevelopment Centre used Icona Solutions’
manufacturing variation simulation and visualiza-tion software, aesthetica, to help it achieve highperceived quality at the same time as cuttingdevelopment time and costs.
In October, 2008, the 59 senior motoring jour-nalists from 23 European countries who make upthe jury for the annual European Car of the Year(COTY) awards chose seven finalists from a totalof 37 contenders for the latest awards. After the
points allotted by the jury during the final round ofjudging had been counted, the Car of the Year2009 award went to the brand new Opel/VauxhallInsignia from GM Europe. The Insignia gathered atotal of 321 points, beating the new Ford Fiestainto second place by the narrowest of margins andthe Volkswagen Golf VI into third place.
An important contributor to the winning of thisaward was the high perceived quality of theInsignia. Perceived quality is a key component ofbrand identity. It describes the first impression acustomer gets regarding the look-and-feel of aproduct, without regard to its functionality. Visiblyhigh quality is an important differentiating factor
6 QMT September 2009www.qmtmag.com
Perceived quality
Very early in the development process
the target specifications could be
defined based on realistic images.
AUTOMOTIVE
Quality is in the eye of the beholder - manufacturing variation simulationand visualization software help GM Opel/Vauxhall’s Insignia win
Car of the Year 2009 award
QMT_Sep09.pdf_1 24/8/09 13:59 Page 6
because it is used by potential customers todecide which products and brands they will con-sider for purchase.
Key to GM Europe’s success here with theInsignia was the use they made of advanced man-ufacturing variation simulation and visualizationsoftware during the car’s development. Known asaesthetica and developed in the UK by IconaSolutions, the software was used from the earlyconcept design stages of the project, enabling thevarious design, engineering and manufacturingdisciplines involved in the project to understandthe manufacturing constraints and to agree on gapand flush conditions and manufacturing toler-ances as early as possible in the overall designand development process. This made it possible toachieve the highest possible perceived quality inthe final vehicle without negatively impacting itsdevelopment and manufacturing costs.
Dimensional managementTen years ago, as part of its focus on quality, inno-vation and affordability, GM Europe created thedimensional management department at itsInternational Technical Development Centre inRüsselsheim, Germany.
The International Technical DevelopmentCentre is at the heart of engineering for GM
Europe. Within it, the dimensional managementdepartment, led by Edgar Lossnitzer, who hasdefined the new perceived quality processes, isresponsible for the management of tolerancesover the entire vehicle development cycle.
Dimensional quality is already defined at Opelat the start of a project in a tracking scheduleknown as the dimensional technical specification(DTS). Dimensional quality is tracked during theentire development cycle, all the way to produc-tion. In the DTS, all gaps and offsets visible to thecustomer along with their nominal values andallowable deviations are specified.
Nevertheless, one of the problems faced by thecompany was that too many gaps were falselyinterpreted through the tolerance simulation. Thisoften led to controversial discussions in the DTSsetting meetings, as well as in follow-up meetings,until a physical model could be produced forreview. This costly and time-intensive processresulted in agreements and decisions being madelate in the process, with the result that there wereoften additional costs involved in implementingthe required design changes.
With a view to overcoming this problem,Lossnitzer and his team set out to fully investigatehow, or if, 3D visualization software could help inthe dimensional management process for theInsignia programme. This brought them into con-tact with Icona Solutions, developer of the innova-tive manufacturing variation simulation and visu-alization software solution, aesthetica, andIcona’s business partner in Germany, Casolute.
Icona Solutions’ aesthetica software applies tol-erances and component deformations directly tothe product’s 3D CAD geometry. These 3D mod-els can then be visualized, in real time, using dif-ferent light sources, colours and materials. This isunlike traditional visualization software, whichcan only visualize a virtual product in its perfect,
8 QMT September 2009
AUTOMOTIVE
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QMT_Sep09.pdf_1 24/8/09 13:59 Page 8
as-designed nominal condition. With aesthetica, arealistic representation of the vehicle as it wouldappear at various points within the range ofassigned tolerances can be produced at a veryearly stage of the vehicle development. Thisenables perceived quality reviews to be carriedout, in which fit and finish problems can be spa-tially represented in real time and solved immedi-ately.
Perceived quality studiesWhen Opel made the decision to implement aes-thetica they were at the very early stage of thedevelopment of the Insignia. Superior design,vehicle dynamics, safety and comfort, as well assuperior aerodynamics and appearance (gap andflush) were all expected from this vehicle.
With the introduction of aesthetica, designreview meetings were routinely carried out in avirtual reality (VR) room in order to show themeeting participants the three dimensional modelwithout it being necessary for any physical mod-els to be built.
aesthetica can be used in every phase of thedevelopment process to accurately and visuallypresent the influence of tolerances on perceivedquality. The parameters used for the simulationsare based on the design and manufacturing data,including the material, fastening scheme and thetolerances. Complex deformation effects such as
arching, bending and distorting are represented,thereby allowing the root cause of problem areasto be identified. These parameters can be changedfreely to enable all possible solutions to be testedin order to achieve the highest possible quality inthe final product.
The first use of aesthetica on the Insignia projectbegan at the early concept stage. As soon as thefirst styling data was released, the first aestheticamodels for the interior and exterior were generat-ed. From this point the digital model would becontinuously updated to accommodate stylingchanges and/or the development progress. Thisprocess continued through the Design &Validation phase up to the final Confirmation andImprovement phase.
Early engineering used the digital models inorder to visualize the effects of the different toler-ances and if necessary, to kick off changes at atime when the cost of change was minimal. aes-thetica made it possible for the calculated varia-tions and their effects to be visualized in 3D.Alternatives could be brought directly into theaesthetica model and the effects of technicalimplementations could be shown immediately inthe 3D representation.
For the interior the concentration was placed,above all, on the area visible to the driver and pas-senger in order to allocate the priorities for the tol-erances in this area. This allowed areas that are
9QMT September 2009
AUTOMOTIVE
www.qmtmag.com
QMT_Sep09.pdf_1 24/8/09 13:59 Page 9
difficult to see or aren’t seen at all to be used tocompensate for build tolerances. Overall, addi-tional attention was given to "forgiving design” inwhich design elements and their optimizationswere evaluated in 3D in the VR room before beingimplemented in physical products.
In the concept phase of the new vehicle devel-opment process it was crucial to include key stakeholders in meetings in order to present the newproduct, as well as all tolerances and the effects ofthose tolerances. As a result, very early in thedevelopment process the target specificationscould be defined based on realistic images.Decisions were able to be released for productdevelopment simultaneously, thereby avoidingfuture surprises, because agreements were morequickly obtained.
In order for discussions in the VR rooms to becompleted as efficiently as possible, a type scriptwas generated beforehand. With this, the area ofthe vehicle, perspective, material combinationand light sources for the visualisation weredefined and stored in aesthetica. As a result, everycondition could be quickly reconstructed. Thenew points and desired notes from the meetingcould also be directly entered and stored in thesame manner. This allowed new ideas to be dis-cussed immediately and either pursued, or reject-ed, partially eliminating the need for physicalmodels and resulting in cost and above all, timesavings.
Depending on the phase of vehicle develop-ment, different goals were pursued in these meet-ings. Here the 3D visualization capabilities of aes-thetica were indispensable because, in theabsence of a physical vehicle, no conclusionscould have been reached otherwise. This wasespecially so in areas of the vehicle in whichmany components interface with each other, forexample on the boot (trunk) lid and the front endof the vehicle, as well as the area where the dash-board and door trim meet. In the development ofthe Insignia Sports Tourer, this area was investigat-ed with aesthetica and its "Gap- / Flush- Fittingtools". Using this, different possibilities for gapand flush could be judged until an image repre-senting an optimal combination could be found.
In the later Design & Validation phase of thedevelopment process attention was always gearedtowards the calculated gap and flush dimensions.The results of these calculations were based onthe assembly processes, component geometry,component tolerances and assembly tolerances.For visualization, separate interior and exteriormodels were required because the developmentphases started at different times.
As a rule only partial models were generated inthe interior area. These models included the frontdoor trim, instrument panel and the Centre con-sole. In order to observe these areas from theviewpoint of the driver and/or passenger, informa-tion from the RAMSIS human models was also
used in these models. Additionally, within the aes-thetica model, rotation points were set in the posi-tion of the eyes in order to evaluate the view in alldirections. With this, sensitive areas could beidentified and the required focus could be appliedto the resulting images. Moreover, this avoided asituation where certain areas were defined asproblematic as a result of being evaluated fromunrealistic views.
In the exterior area, the tolerance calculationsthat were categorized as critical were visualizedon the Powerwall in the VR room using the “Gap-/ Flush- Fitting Tools“ of aesthetica and presentedto the decision makers. This provided a greatadvantage because the meeting participants easilycould see how large the adjusted gap dimensionswere.
As the models became more advanced furtherattention could be applied to elements such asvisible structural items like screws, rivets or ribswithin the gap, clip connections of componentswithin the visible area, visible sub-materials such
as sealing foam or glue, and elements visiblethrough transparent components such as head-lamps. This all helped to improve the overall visu-al appearance, or perceived quality, of the finalvehicle.
As a business that has actively integrated dimen-sional engineering into the vehicle developmentprocess for more than 10 years, Opel was lookingfor a tool to support decision making. IconaSolutions’ aesthetica software was developed as avisualization tool that enables vehicles to bedeveloped in a cost efficient and effective way.Although some people were initially critical of thehigh investment needed for the software and 3Dvisualisation on a Powerwall, once it becameclear how easily concrete decisions could bemade, they were convinced of the value.
Communication of necessary changes to man-agement has improved, decisions are made fasterand as a result, development costs are saved.Considerable resources have been saved by elim-inating the need for physical validation models,which together with the time savings have morethan compensated for the acquisition costs of thesoftware. �
www.iconasolutions.com
10 QMT September 2009
Since introducing aesthetica into Opel,
there have been no more long-winded
and time-consuming discussions regarding
a few tenths of a millimetre.
www.qmtmag.com
AUTOMOTIVE
QMT_Sep09.pdf_1 24/8/09 13:59 Page 10
ZEISS Technology is now muchcloser than you think...
Carl Zeiss Ltd.
Division of Metrology
We make it visible
2 Hadrians Way
Glebe Farm Industrial Estate
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Phone: 01788 821770 Fax: 01788 821755
Email: [email protected]
Website: www.zeiss.co.uk/metrology
The NEW Carl Zeiss DuraMax gives
you the power of ZEISS Technology in
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DuraMax offers all the benefits you
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replacement tool for gauges and
manual CMMs.
To find out how you can benefit,
visit: www.zeiss.co.uk/DuraMax
QMT_Sep09.pdf_1 24/8/09 13:59 Page 11
PRODUCTS
www.qmtmag.com QMT September 200912
DATA MANAGEMENT
Precision measuring is the firststep in displaying the quality ofworkpieces. The second is theseamless documentation andeffective management of themeasured values. The VWengine works in Chemnitzselected the Master ControlCentre (MCC) from Carl Zeissfor the effective and reliablemanagement of measurementdata. This data is now avail-able anytime, anywhere.
Without digital capture anddocumentation, the amount ofpaper would increase propor-tionally to the number of
measuring machines. This ishow it was in the past at theVolkswagen factory inChemnitz, “because weworked with printed measure-ment logs,” says MatthiasKurth who is responsible formeasurement planning. Thiswas before the MCC wasinstalled, which features aMeasurement Log Archive,Production Data Acquisition(PDA) and OnboardDiagnostics software modules.Now, anyone with the properauthorization can access alldata available on the MCC
from their computer.The developers at Carl Zeiss
have matched the softwaremodules to the requirementsof everyday use. However,every now and again, modifi-cations may be required by theuser. This is where the modu-lar concept comes into play.“We used a modular designfor the MCC to enable us to(relatively) easily implementcustomer-specific modifica-tions,” says Wolfgang Thalerfrom Carl Zeiss 3D MetrologyServices.
A glance at the VW enginefactory in Chemnitz provides agood example of everythingthe MCC and its modules arecapable of: all authorized per-sonnel can access the meas-urement log database on thecentral data pool. Long-termdocumentation is also avail-able. The management func-tion enables not only profes-sional data backup, but alsotraceability of all measurementplan modifications. All meas-urement plans for all measur-
ing machines are saved in themeasurement log databaseand approved for volume use.This guarantees that onlyapproved and up-to-datemeasuring programs are used.
The PDA and OBD softwaremodules provide an effectivemeasuring machine manage-ment system. It is now possibleto access the operating statusof each machine. This allowsthe user to monitor not onlythe temperature gradients, butalso the level of utilization,which is an important criterionin measurement planning.Additionally, a knowledgedatabase, which ensures thecentralized provision of oper-ating manuals and generalmetrology know-how, was set-up. This is based on the exist-ing MCC data. The new sys-tems enabled the VW factoryto meet the increaseddemands of highly flexibleproduction without additionalpersonnel expenses.
www.zeiss.de
Measurement dataavailable anytime,anywhere at the VWengine works inChemnitz, Germany.
QMT_Sep09.pdf_1 24/8/09 13:59 Page 12
TURBOCAM is a preferred supplier of bothproduction and prototype bladed parts toaerospace, automotive and industrial turbo-
machinery OEMs. Constantly changing surfacegeometries, pin-wheeling shapes and tight, intri-cate features make turbomachinery components— impellers, blades and blisks — some of indus-try's most complex and exacting shapes. TURBO-CAM International achieved leadership in thisspecialized field by mastery of five-axis machin-ing and five-axis programming software.However, efficient inspection of ever increasingnumbers of complex parts was frustrated by slow,tedious, stop-and-go measurement inspection ona legacy 3+2 axis coordinate measuring machine(CMM).
Changing 3-D part geometries required manydifferent probe orientations, plus frequent stylusand tip changes for difficult to reach features,
explains Dave Romaine, quality assurance man-ager. "We would have to stop the CMM and cali-brate each re-orientation of the probe. That was
compounded as we inspected multiple bladesaround a part."
As five-axis experts, TURBOCAM staff werequick to see the potential of a scanning systemfrom Renishaw that makes possible automated,programmable five-axis measurement at speedsand accuracies never before possible by CMMs.The Renscan5 scanning system offered the capa-bility for continuous five-axis interpolated motion,
13QMT September 2009
Leader in five-axis turbomachinery production, TURBOCAM, has adopted thefive-axis Renishaw inspection system to achieve faster throughput, big program-
ming reductions and greater CMM utilization.
Renscan5 transformed partmeasurement and inspection
from a bottleneck to an enabler.
3D MEASUREMENT
Turbo-charged inspection
www.qmtmag.com
QMT_Sep09.pdf_1 24/8/09 13:59 Page 13
comparable to TURBOCAM's five-axis machinetools.
In January 2007 TURBOCAM became one ofthe first adopters of the new Renscan5 continuousfive-axis inspection capability. Installed on a newWenzel LH8.10.7 bridge-type CMM at the com-pany's Dover, New Hampshire, USA plant,Renscan5 transformed part measurement andinspection from a bottleneck to an enabler.
High-speed continuous probing routines arereducing programming time, set-up time andmeasurement time by 50 percent and more.Besides faster throughput, Renscan5 time-savingsallows the taking of many more data points forgreater measurement precision and frees up CMMtime for qualification of turned blanks and in-process checks before final machining passes.
Those advantages led TURBOCAM in early2008 to become the first company worldwide toadd a second Renscan5 CMM, a larger WenzelLH10.12.8, this time at a new facility in nearbyBarrington. In this new facility, Renscan5 is an"essential resource" says Romaine, that is beingdeveloped to support higher-throughput produc-tion generated by around-the-clock, reduced-staffmanufacturing.
High speed measurementRenscan5 uses two patented hardware break-throughs to speed part checking, generate moredata points for analyzing part form, and increaseavailable CMM run time.
Active" probe head Named REVO-, a powered head provides infinitepositioning capability between simultaneouscoordinated motion in vertical and horizontalrotary axes. This allows the low-mass two-axishead, a 3-D measuring device in its own right, toperform most of the motion during inspection rou-tines. Infinite positioning allows continuousmotion, optimizes part access, and delivers highaccuracy part measurements. The active headavoids dynamic errors caused in rapid accelera-tion/deceleration of the larger mass of a CMMstructure. Low-mass, low-inertia design allowsRenscan5 to measure at up to 500 mm/sec vs.conventional CMM scanning that is typically lim-ited to 5-15 mm/sec to avoid dynamic errors.
REVO repositions continuously on the fly,simultaneous with measurement, unlike indexingheads which first must be locked into position,after which the CMM provides the measuringmotion. On complex parts, says Romaine,"Hundreds of calibrations have now been elimi-nated, saving us hours of calibration time."
Renscan5 allows the CMM's three-axis platformto be used primarily to "rapid" the REVO head intoposition for measurement. Where CMM motion isrequired for a measurement routine, it can usual-ly be limited to a single linear axis and performedat constant velocity, minimizing dynamic effects
QMT September 2009
3D MEASUREMENT
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on accuracy from acc/dec and inertia.
Laser-corrected probingREVO employs industry's first laser-corrected "TipSense" probing. A laser mounted within the headsends its beam down a hollow stylus to a reflectorat the tip. The return beam is received by a posi-tion sensor and any deflection is used to calculatetrue tip position. This allows REVO to perform acomplete part inspection routine in a continuousoperation without recalibration or stylus changes."Only one probe is typically used to measure anentire part with no tip change time," saysRomaine. Tip Sense probes deliver 1 micron accu-racy at 250 mm from the axis of rotation. Sizes areavailable providing probe reach to 500 mm.
While the previous 3+2 axis CMM at TURBO-CAM provided a two-axis head, vertical changesin probe angle could only be made in 2.5 degreeincrements, then calibrated and fixed at the posi-tion for measuring. "As we inspected more bladesaround a part, such as a blisk, it would obviouslyrequire more and more probe orientations and
calibration. Programming, access, stylus change,and calibration were incredibly painful," notesRomaine.
Confidence in blade geometry TURBOCAM uses Renscan5 for both point-to-point probing to verify feature location and sizeand for contact scanning of part surfaces for shapeand form data. "On point to point we are able togather more data simply because the head canorient to any angle and it's a very simple set-up toget more points," says Romaine.
Renscan5 high-speed scanning greatly increasesdata points. "Previously we might collect 50 or100 points spaced over a blade," he says. "Nowwe can collect hundreds or thousands of pointswith a scan." In scanning mode, the probe movescontinuously, adjusting to programmed changesin part geometry. REVO gives TURBOCAM up to4000 points/sec in scanning mode.
"Increased point data allows us to see a morecomplete picture of what we're manufacturing,"says Romaine. "We can see deviations better asthey increase and decrease along a blade oraround a part. This lets us better trouble-shoot ourmanufacturing process." As example, he notes thatTURBOCAM has been able to detect toolingbreakdowns based on Renscan5 surfacing data.
Helping to reduce measurement time for higher
15QMT September 2009 www.qmtmag.com
We can see deviations better as theyincrease and decrease along a blade or
around a part. This lets us better trouble-shoot our manufacturing process
3D MEASUREMENT
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utilization, the Renscan5 system includes a UCC2universal CMM controller with patentedMoveScan™ software that synchronizes,smoothes and speeds motion between the CMMand the REVO head. MoveScan drives the probeto the surface of the part in the shortest distanceby looking ahead to go-to points and blendingmoves into smooth, continuous motion.
Reduced programming times Parts inspected on the CMMs range from smallimpellers just 2" in diameter to 36" diameter,multi-vane components. TURBOCAM producesmore than 400 different bladed part designs a yearfor compressor, turbine and pump OEMs.
Just as important as the inspection advantages,"stresses Romaine, “are the programming benefits.This has been exciting. We've been able to applyour five-axis machine tool programming methodsto drastically reduce programming time for five-axis inspection. This is only possible because ofthe infinite indexing of REVO and its programma-bility through the I++ DME protocol."
Renscan5's I++ interface gives the UCC2 con-troller cross-platform compatibility with measure-ment software packages and maintains userchoice of CMM and software. On complex partssuch as blisks (integral hub and blades machinedfrom a monolithic blank), notes Romaine, "Whatused to take three days to program now takes
three hours. The biggest time savings have comein programming and set-up, even more than runtime."
The ability to apply five-axis programmingexpertise makes it much easier and faster to pro-vide programs for part inspection, increasingmachine utilization for a wide range of parts, hesays. While Renscan5 integration is still evolving,he estimates the CMM utilization has alreadyincreased between 30 and 50 percent.
By automating and simplifying inspection,Renscan5 has changed not only utilization, butalso uses and users of CMM inspection, accordingto Romaine.
First, it greatly reduces need for operator inter-vention in changing probe orientation. "This hasbeen a big benefit and is definitely one of the sell-ing points of the machine," he says. Second, thesimplicity of Renscan5 in conjunction with theCMM software makes it possible for machinistsand operators to directly measure in-process partswithout the need for an inspector to run the CMM."They simply need to put the part on the table andcall up the appropriate program," he says. "We doinspections of turned blanks and perform in-process check before final machining passes," henotes. �
www.renishaw.com
16 QMT September 2009www.qmtmag.com
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QMT_Sep09.pdf_1 24/8/09 13:59 Page 16
PRODUCTS
www.qmtmag.comQMT September 2009 17
CMMs
Aerospace - biggestMetris CMM everA leading aerospace manufac-turer recently took delivery ofone of the widest ever bridgestyle co-ordinate measuringmachine (CMM) manufacturedin the world. CMM manufac-
turer, Metris, developed thegantry CMM with a measure-ment volume of 6m x 6m x3m, to run geometry verifica-tion on large aerospace com-ponents and assemblies.
The gantry style CMM per-forms with an accuracy of 5microns, which is achieved by
the use of ceramic guide waysfor the beam and spindlecomponents. Ceramic is anideal material for metrologybecause it offers the ultimatein stiffness combined with lowweight and excellent thermalproperties. Used in combina-tion with double air bearings
that prevent torsion, thisceramic Metris LK gantry CMMprovides high and long-lastingmeasurement accuracy. In itsfinal location, the granite railswill be positioned on a pur-pose built ‘U’ shaped concretefoundation in order to providethe 3m vertical measurementrange.
Intensive collaboration withthe customer enabled Metris todetermine the final configura-tion and build the LK V60.60.30 GP to match thecustomer’s application needs.
www.metris.com
Hexagon Metrologyunveil a new productline - Standard Gage.Hexagon’s Standard Gagerange comprises of traditionalmeasuring instruments such ascallipers, micrometers, boregages and indicators.Hexagon say the range willexpand to include products inthe fields of contact and opti-cal measurement, with thefirst being a vision machine,the Visual 250. Already shown
CHECoordinate Metrology
Laser Calibrations for larger coordinate measuring
machines and machine tools
CMM Reverifi cations to ISO.10360-2
plusService / Repairs / Upgrades
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Call us on:Tel: 01527 558255Fax: 01527 558244
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QMT_Sep09.pdf_1 24/8/09 13:59 Page 17
at Control Exhibition inGermany and Subcon in theUK. Hexagon say the Visual250 is low cost entry systemretailing in the UK at about£8K.
Standard Gage products aremanufactured mainly in Asia.Each instrument is deliveredwith a control certificate, prov-ing its conformity to technicalspecifications.
Hexagon say the StandardGage line fills the gapbetween low-cost productswith an uncertain quality, andPremium class instruments,such as those available fromTESA.
www.standardgage.com
High speed surfacemeasurementFollowing the acquisition ofSteintek GmbH, Wenzel Grouphas launched a high speedmeasurement and digitizingSystem (photo below).
The system is based on theWenzel Steintek white lightsensor, with a high precisionswivel head for sensor posi-tioning and high precision
rotary table for part position-ing. Suited to a productionchecking role in a workshopenvironment, the high speedsystem achieves 180 pointsper minute in point measure-ment mode and in scanningmode, 4,200 points perminute. This translates to 3minutes measuring time for10aerofoil sections, including axisalignment and reporting, forexample.
This is a non contact whitelight solution and makesmeasurement of soft, sensitiveor rough surfaces possible. Arange of surface finishes areeasily handled with no coatingrequired. These include shiney,rusty, black, white, machinedor polished surfaces.
Applications include themeasurement and reporting ofturbine blades, nozzle guidevanes and blisks - any compo-nent that require surfacemeasurement or digitizing.
www.wenzel
Heavy duty console-typeCMM Hexagon Metrology’s DEA
BRAVO C (Console Version)horizontal measuring machinebuilds on the its BRAVO HPand BRAVO HD line.
The BRAVO C is a cost-effective solution for flexibleand accurate dimensionalinspection of thin-walled com-ponents, ideal for mid-sizeparts in industrial environ-ments. The guideways locatedon the side of the machinebase (Console architecture)allow the arm to be moved
fully outside of the workingarea. This allows for optimalaccess to the work area forsimple part loading/unloadingoperations. The cast ironmachine table features theexclusive three-point supportsystem, which eliminates theneed for costly dedicated foun-dations, and makes the instal-lation on vibration damperseasier.
The BRAVO C offers ameasuring range from 3000to 5000 mm (X axis), 1400 or1600 mm on the Y axis and1600, 2100 or 2500 mm onthe Z axis.
www.dea.it
New version of Delcam’sPowerINSPECT inspec-tion softwareDelcam has launched a newversion of its PowerINSPECTinspection software for check-ing the dimensions of parts,prototypes and tooling againstCAD data. The new versionincludes a range of enhance-ments to make the softwareeasier and more flexible touse.
The most obvious change inthe new version is a complete-ly new interface for undertak-ing "simple” measurements.This will make it much easierto undertake basic tasks, suchas measuring the distancebetween two points or twoplanes, or the centres of twocircles, or checking the thick-ness of a section.
It has also been made easi-er to add or delete points
during an inspection from aset of measurements definingany feature. Points mightneed to be added to collectextra data from a suspectarea, while "rogue” measure-ments can be deleted to pre-vent them affecting the over-
all inspection result.www.delcam.com
Economic fixturing fornon-contact scanningpartsNVision Inc. and FixLogix LLC
have partnered to provide anew easy-to-use and economi-cal modular part-holding sys-tem designed especially fornon-contact scanning. TheFixLogix part-holding systemuses a t-slot fixture plate withintegrated components tostage the part on the machine.
The t-slot plate has a clampledge around the perimeter,allowing easy lock-down withtoe-clamps. New “near zero”force clamps feature an inno-vative self-wedging designideal for trapping soft or frag-ile parts without distortion. TheFixLogix modular part-holdingsystem provides multi-axis infi-nite positioning of locatingcomponents, which simplifiesfixture construction. The frameis laser engraved with refer-ence scales along the T-slots,providing clear documentationof the fixture setup for easyrepeatability. The modularpart-holding system worksequally well with optical scan-ning systems mounted ongantries and portable coordi-nate measuring machines(CMM).
NVision provides theFixLogix modular part-holdingsystem as part of a completepackage with their non-contactoptical scanning systems.These include the NVisionHandHeld scanner, MAXOS,
CMMs
QMT September 200918 www.qmtmag.com
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and MobileScan.E-mail: [email protected].
www.nvision3d.com.
Replaces portable armCMMs?The Opti-Probe, fromInspecVision, is a new visionsystem which aims to super-sede CMM arms in both capa-bility and cost.
The Opti-Probe (photoabove) is a light weightportable CMM which uses ahand held probe in conjunc-tion with a very high resolutioncamera. The hand held probehas markers which are imagedand located by the camera.The image is then downloadedto a computer which then cal-culates the 3D location of thedevice, allowing measure-ments to be taken.
This arrangement has signif-icant advantages over tradi-tional CMM arms. It has nomoving parts and is thereforerobust and flexible; it can beused in a factory environment.Accuracies quoted for the sys-tem are up to 30 microns.It is very easy to use (no bulkyand fragile arm to consider)and can be fully recalibratedon-site with little training. The Opti-Probe can be used tomeasure large or small vol-umes, from 1 m3 to 50m3 andis extremely competitivelypriced, with prices starting ataround £10 000
www.InspecVision.com
Formidable trackerThe Leica TDRA6000 is themost accurate total station
ever designed for industrialuse, claim Leica Geosystems..This new Leica laser stationhas the ability to automaticallytarget both CCR and tape tar-gets and can measure withouttargets, maintaining a typicalreflectorless accuracy of 1mm. Optimized for use within300 meters and combined
with the Leica GeosystemsPowerSearch module, the LeicaTDRA6000’s tracking perform-ance is formidable.
An all new Leica Geosystemsproprietary direct drive tech-nology has been designedfrom the ground up for thisnew sensor. Based on Piezotechnology, the direct drivesenable high speed motoriza-tion and acceleration, at up to4x the previous generation,but still allow sub micron levelfine positioning. This technolo-gy has very low power con-sumption, requires almost nomaintenance and is nearlysilent.
www.leica-geosystems.com/metrology
CMMs
QMT September 2009
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PRODUCTS
www.qmtmag.com QMT September 200920
PORTABLE CMMs
A Faro Gage speeds up robotcalibration and measurementat Parallel Robotic Systems,PRSCO. PRSCO designs andproduces high precision posi-tioning systems for use in awide variety of applicationssuch as industrial, biomedical,simulation, and water jet cut-ting. Headquartered inHampton, New Hampshire,USA, PRSCO’s 6-degree offreedom robots are based ona Stewart Platform or Hexapod(six-legged) system. This offershigh load capacity and rangeof movement while maintain-ing a high degree of precisionand repeatability. Thesedevices are used to provideeffective solutions to difficultmotion problems, to eliminate
errors in automated weldinglines, and to advance testingin bio-mechanical research..
When building Hexapodrobots, there are six spheresattached to the Hexapod’stable and another six attachedto its base. It is critical thatPRSCO accurately locate eachsphere’s centre. The distanceof each sphere’s centre to areference point and plane andthe lengths of the struts thatconnect each sphere must beprecisely measured.
Using a stationary coordi-nate measuring machine(CMM) provided accuratemeasurements, but acquiringone large enough for theirneeds wasn’t economical.Some robots are so big, in
fact, that even outside metrol-ogy services weren’t an optionbecause of limited local avail-ability and the high cost oftransportation. The bottomline: PRSCO couldn’t qualifytheir robots’ performance con-veniently, efficiently, or eco-nomically using fixed CMMs.
The FARO Gage-PLUSproved to be the solution thatgave PRSCO the features andbenefits not found in fixedCMMs. The Gage provided theneeded accuracy of up to.0002” (.005mm) – withoutthe need for regular calibra-tion as with fixed CMMs – andis much more efficient anduser-friendly.
With the Gage, PRSCO cannow see an actual representa-tion of the behaviour of theirHexapods’ moving tables andcan compare geometric char-acteristics between features.They use the Gage in their cal-ibration phase and in theirqualifying procedure, both of
which are required for everyrobot.
R.O.I.“Typically, it took about sixhours to calibrate each robotusing outside resources,including travel time,” saidengineering manager, AndyChui. “With the FARO Gage,this has been reduced to onehour and we can re-measurethe parts anytime we want. Inmy opinion, the convenience ispriceless when we must havesomething measured immedi-ately.”
On occasion, customersrequest robot re-calibrationchanges be made on-site atthe last minute. Without theGage, the entire robot wouldhave to be removed from itsmounting structure and sent toa CMM large enough to per-form the measurement. Theportable FARO Gage elimi-nates that burden.
www.faro.com
Robot calibration -limitations of fixedCMMs overcome
QMT_Sep09.pdf_1 24/8/09 13:59 Page 20
PRODUCTS
www.qmtmag.comQMT September 2009 21
MICRO & NANOMETROLOGY
Improved observationand imagingThe Nikon LSI inspectionmicroscopes, Eclipse L200Nand L200ND, build on thehigh resolution and precisionof the Eclipse L200 and L200Dseries. The L200N andL200ND offer improved obser-vation and operating perform-ance, providing images withgreater contrast and higherresolving power. Used inde-pendently or in combinationwith wafer loaders, the L200series performs precise opticalinspection of wafers, photomasks, reticules and othersubstrates.
Featuring an ergonomicdesign, main controls arelocated at the front of the basefor easy access, allowing stagemovements and focusing to becarried out with ease and min-imising fatigue during lengthyobservations. A tilting trinocu-lar eyepiece tube enablesobservation at optimum eyelevel to ensure a comfortableviewing position. Quick andeasy microscope operationwhile viewing samples is possi-ble. The L200N series allowseasy and accurate focusing onlow-contrast samples, such asbare wafers, simply by insert-ing a focusing target in theoptical path. Up to six objec-tives can be mounted on therobust motorised nosepiecewhich also minimises imageshifting even between highmagnifications.
Control of the camera,peripherals and microscopeare all integrated within NIS-Elements imaging softwarewhich offers high-qualityadvanced image acquisition,processing and analysis. EasyUSB connection offers high-
speed data transfer.www.nikoninstruments.eu
Optical profiling systembased on spinning discThe Veeco Confocal Metrology(VCM) Optical Profiler Systemsprovide a compact and easy-to-use non-contact metrologysolution for applicationsrequiring data acquisition fromsteep slopes, high surfaceroughness, or beneath trans-parent layers. VCM ProfilerSystems are based on spinningdisc architecture and employwhite light as the excitationsource, enabling faster, moreaccurate and repeatablemeasurements than competingconfocal systems.
“Veeco has a strong her-itage of providing world-class,white-light optical profilers in avariety of configurations, fromtable-top models to fully auto-mated production floor sys-tems,” said Mark R. Munch,executive VP, Veeco Metrology.“Our new VCM confocalmicroscopes continue this tra-dition of scalable white-light
optical instrumentation, pro-viding our research and indus-try customers with a suite ofmetrology options for difficultsample requirements and avariety of sub-millimetre appli-cations.”
Veeco's VCM series of confo-cal microscopes allow for 150,200, or 300 millimetres oftravel, and can be configuredfor either manual or automat-ed operation. The VCM Systemsoftware has an optionalstitching interface that makesstitching multiple data setssimple and automatic, provid-ing high-resolution imaging offeatures requiring a largerfield of view.
www.veeco.com
Unit 15, Bordon Trading Estate, Bordon, Hampshire GU35 9HH Telephone: 08708 50 90 50 Fax: 08708 50 90 60 www.bowers.co.uk [email protected]
As exclusive UK distributor, Bowerscan deliver Gagemaker’s
industry-standard thread inspectionproduct range
METROLOGY SOLUTIONS
THAT PERFORM….
Bowers’ range of flexible andadaptable bore gauges areperfect for use in the mostdemanding environments
Partners in Precision
Bowers has launched some great Special Offers acrossits range of Precision Measuring Solutions.
For more information visit www.bowers.co.uk/current-offers
QMT_Sep09.pdf_1 24/8/09 13:59 Page 21
IBS Precision Engineering (IBSPE) takes the measurement oflarge complex parts tonanometre level with the intro-duction of the multi-probeISARA 400 3D coordinatemeasuring machine (CMM).This has been achieved byincreasing the measuring vol-ume of its ultra precision 3DCMM by a factor of 40 to to400 x 400 x 100 mm3 - a sig-nificant volume in view of the45 nanometre (nm) 1D meas-uring uncertainty in all threedirections.
Using three planar mirrorlaser interferometers, ISARAmeasures the position of anobject on a table according tothe Abbe principle (ie the func-tional point is in line with themeasuring line to avoid errorsin parallax). Positioned in onestiff frame with the probe, thethree planar mirror laser inter-ferometers have their virtualintersection point coincidingwith the measuring point ofthe probe
The product table - madefrom Silicon Carbide (SiC) forits stiffness and thermal stabili-ty - is placed on a mirror tablethat can be moved in X and Ydirections over a granite plateusing porous media air bear-ings. A monolithic block ofZerodur deposits the reflectivecoating directly onto threeextremely flat surfaces to formthe three mirrors; the mirrorblock assembly is directly con-nected to the machine and
calibrated within it, allowingfor both the flatness and themutual perpendicularity ofeach mirror.
The metrology frame con-taining the three laser interfer-ometers and the probe movesin the Z direction using airbearings, over a granite guid-ing surface. The interferome-ters always point to the centrepoint of the probe tip (fulfillingthe 3D Abbe principle) whilethe metrology frame (alsomade from SiC) is stiff with nointernal degree of freedom,avoiding the need for extrabearings.
The base frame consists oftwo granite guiding units - onefor the X-Y system and one forthe Z - joined to form a stablebase frame. The air bearing-equipped direct drives for allthree directions are eachmounted separately from thepart they drive.
ISARA 400 is fully equippedfor ultra precision performanceand user convenience.Thermal shielding preventsmeasurement errors becauseof differences in thermalexpansion. Three vibration iso-lators counter disturbancesdue to environmental vibra-tions while automated producthandling prevents damage tocritical parts that could becaused by manual operations.The machine comes with aseparate Abbe probe align-ment tool and a camera formeasurement visualisation -especially useful during prod-uct alignment – in addition todust protection and acousticinsulation.
IBS PE’s Triskelion ultra-pre-cision touch probe will be ini-tially implemented in theISARA 400. Its design address-es the problems associatedwith most conventional probe
systems: measuring uncertain-ty, probing forces and probetip being too large. An AFM, anon-contact probe or opticalprobe, can also be implement-ed in the machine.
For all axes, the 1D measur-ing uncertainty is 45 nm,whereas the full-stroke 3D
measuring uncertainty totals100 nm. ISARA 400 can beused, for example, to measurelarge, free-form optic compo-nents. The large measuringvolume, in conjunction with theautomated product handler,allows the use of trays contain-ing several products to bemeasured in one run. TheISARA 400 will be available bythe end of 2009.
Email: [email protected]; www.ibspe.com
Quantum leap for microcalibration Bowers Metrology, UK agentfor the Swiss Metrology manu-facturer Trimos, has launchedthe Labconcept Nano range ofultra-accurate, CalibrationMachines.
Able to calibrate a widerange of gauges and measur-ing instruments, the
Labconcept Nano can checkinternal and external dimen-sions fully automatically. Allfunctions, such as the unit’sdisplacement speed, measur-ing force, probing movement,measuring carriage lockingand temperature compensa-tion are automatically con-trolled by advanced electron-ics. Every possible user influ-ence is eliminated from theNano’s findings, resulting inhigh levels of measuring accu-racy and repeatability.
The new Trimos range con-sists of 3 machines with appli-cation ranges of 350 mm, 600mm and 1100 mm.Maximum permissible errorsare 0.07 + L(mm)/2000 withrepeatability and resolution of0.03 um and 0.00001 mm(0.00000004 inches) respec-tively.
Email: [email protected] www.bowers.co.uk
MICRO & NANOMETROLOGY
QMT September 200922
Nanometric precision measurement oflarge complex parts
Labconcept NanoCalibration Machine
www.qmtmag.com
QMT_Sep09.pdf_1 24/8/09 13:59 Page 22
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BMW Group’s new Aerodynamic Test Centre(ATC) claims to be the world’s most modernfacility of its kind throughout the entire
automotive industry. The ATC is designed to opti-mise the aerodynamic qualities of future models,allowing tests under very realistic conditions bothin the large wind tunnel and in the Aerolab. ATCcomprises a wind tunnel serving to analyse vehi-cles in their original size. To reproduce the mostimportant effects and phenomena when drivingon the road, the road surface is modelled througha simulation process using five rolling tracks.
A second wind tunnel, the Aerolab, allows theengineer to move the models tested from oneposition to the other by means of a control systemoperating in all directions above the world’slargest rolling road in a wind tunnel. This serves toanalyse vehicle flow conditions under all kinds ofcircumstances, applying a concept already usedfor a number of years in motorsport. Now aerody-namics and driving dynamics may interact and becombined with one another in the development ofproduction cars.
The permutations of scenarios available, as wellas the precision of the test processes applied at theATC, offer a standard unique for a facility of this
kind, say BMW. Both wind tunnels, to mentionjust one example, are able to generate an air flowvelocity of up to 300 km/h or 186 mph, for the firsttime providing exactly the right, correct physicalconditions for the measurement of true-to-scalemodels.
In all, the BMW Group has invested someEuro 170 million in the construction of theAerodynamic Test Centre and thefacilities/equipment used. Over a three year
period, the five-floor building has been con-structed on a piece of land measuring approxi-mately 25,000 square metres, or 6.2 acres, andwhich is located in the immediate vicinity of theMunich FIZ Research and Innovation Centre.The futuristic design of the Centre provides aclear hint, right from the beginning, that thetechnology inside is very special indeed.
24 QMT September 2009
BMW Group has made an euro 170 million investment in the future with itsadvanced Aerodynamic Test Centre in Munich.
ATC is now able for the first time torender and analyse the interaction
of a car with other vehicles, forexample, when overtaking
TESTING SUPPLEMENT
Optimal quality at BMW
www.qmtmag.com
QMT_Sep09.pdf_1 24/8/09 14:00 Page 24
One example of this distinctive look and archi-tecture is the round contour of the fan that pro-vides the horizontally arranged air flow ring in themain wind tunnel and which is clearly recognis-able on the southern side of the building. The ver-tical air flow ring for the model wind tunnel alsostands out clearly in the centre of the ATC.
BMW’s EfficientDynamics specialists used towork at no less than five different locations beforemoving into the new Test Centre, travelling up to20 kilometres in order to work together in thewind tunnel. Now, by putting all these specialiststogether in one building, the BMW Group ensuresdirect contact with extremely small distancesbetween the various specialists and has estab-lished new processes for highly efficient interac-tion and cooperation. In all, some 500 specialistsin BMW EfficientDynamics will be workingtogether in the new building.
Closer to reality. By building the ATC, the BMW Group is givingeven greater emphasis to the ongoing enhance-ment of aerodynamics as an essential corner-stone of the EfficientDynamics philosophy.Optimised aerodynamics have a direct impacton the car’s fuel economy and emission man-agement, a reduction of air drag by 10 per centoffering the customer a reduction in fuel con-sumption on the road by more than 2.5 per cent– and even such an at first sight “insignificant”improvement is of great importance to the BMWGroup as part of an overall package for theenhancement of efficiency.
The large wind tunnel in the new AerodynamicTest Centre where car models are tested in theiroriginal size together with prototypes and produc-tion models, allows the most precise and realisticrendition of actual air flow conditions on the road.Here the flow of air generated by a fan measuringno less than 8 metres, or 26.2 feet, in diameter,after being diverted twice, acts directly on thevehicle held down in its measuring position.Thanks to the size of the measurement facility, theprecise direction of air flow downstream of the fan
and the nozzle opening of up to 25 square metres,or 269 sq ft, flow conditions are absolutely realis-tic and are not distorted in any way.
The wind tunnel comes with a special configu-ration of rolling tracks incorporating five differenttrack sections. The wheels of the vehicle on themeasuring track run on small rolling sections serv-ing to simulate the actual rotation of the car’swheels. These rolling tracks may be varied inwidth and length, and therefore adjusted to vehi-cles of various sizes. A wider track between theturning wheels serves additionally to render theflow of air beneath the car.
Using these five rolling tracks, the test engineeris able to determine the so-called flow-split, that isthe share of air flow above and beneath as well asat the side of the vehicle, far more precisely thanin a conventional wind tunnel.
The central rolling track may be varied in width,in accordance with the wheel track of the vehiclebeing examined. And measuring 10 metres, oralmost 33 feet, in length, the central track alsooffers ideal conditions for simulating the changesin air flow typically encountered on the road.Ultimately, therefore, the development engineercan see exactly how the optimisation of specificdetails affects air resistance, the aerodynamic bal-ance of the vehicle, as well as the supply andextraction of cooling air.
Maximum flow velocity in the new wind tunnelis 300 km/h or 186 mph. This allows realisticmeasurements also of racing cars travelling at highspeeds.
The ATC is now able for the first time to renderand analyse the interaction of a car with othervehicles, for example when overtaking, thus offer-ing yet another new benefit in the development ofproduction cars.
To-date, such tests could only be conducted onthe test track with cars almost completely devel-oped in every respect. Now, the knowledgegained in this process can be fed back into thedevelopment process much earlier, serving toeffectively optimise a new model right from thestart. �
QMT September 2009
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Looking at the electronic product develop-ment landscape in India today, we see thatseveral industries have grown substantially in
the last few years. As electronic product develop-ment in India expands, the opportunities thrownup for testing the quality of these products areimmense. Testing labs in India are trying toaddress this need in the industry.
Considering the mobile phone industry in Indiaas an example, the country added 15.4 millionmobile subscribers in the month of January 2009.This has taken the total number of activated wire-less lines to 362.3 million. And adding to this thecountry's 37.75 million fixed lines, takes India'stotal number of telephone lines to more than 400million. When product sales volumes are thislarge, even minor quality issues in mobile hand-sets lead to large volume of field recalls resultingin a significant impact on the profitability of man-ufacturers.
Hence, the product needs to undergo qualitytesting in the initial design stage itself to ensurefewer respins. EMI/EMC (ElectromagneticInterference/Electromagnetic Compatibility) test asa part of quality testing comes into play at an earlystage to ensure good EMI/EMC performance of the
product. EMI/EMC test is also applicable to vari-ous other industries like automotive electronics,Avionics, Telecommunication, IndustrialAutomation etc.
Design for EMI/EMC compliance starts with athorough survey of all applicable standardsmandatory for the product in all targeted geo-graphic regions. Owing to each standard havingspecific requirements, the consultant will need toidentify the superset of different standard require-
ments and various testing needs. In the next step,the consultant advices on selection of compo-nents, to get the best EMI performance. However,there will be some tradeoffs, such as price, whichneed to be made to match requirements. As anext step, the consultant analyses the mechanicaland electronic design and continuously monitorsto see that the changes from reviews are imple-
26 QMT September 09www.qmtmag.com
Testing quality in India
Reliability of CFL improved 4 timesdue to increase in design margin intemperature withstanding capability.
Electronic product testing and quality - the key to electronic productdevelopment in India. By Prasad Bhatt – vice president, Product
Engineering Services, Wipro Technologies
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mented. The consultant plans for testing softwarewhich could exercise worst case scenarios.
Here, module-wise activation and functionalityhelp in debugging issues. During the pre-compli-ance tests, the consultant helps in planning thetests, interpreting the test results and finding suit-able solutions to match the design team’s needsand constraints. EMI/EMC pre-compliance & finalcompliance tests are provided by labs, such asWipro’s recently launched ‘Tarang’. The teamhere provided consultancy and testing services toa leading electric car manufacturer who was tar-geting to enter a new geographical market. Thebattery management system of the electric car wastested for the standards required in the new geog-raphy.
Design for Reliability practices are also imple-mented rigorously in electronic product designtools and processes prevalent in commercial anddefence industry along with EMI/EMC testing.Prevention based techniques deployed by reliabil-ity consultants include Derating Analysis, MTBFPrediction, Reliability Block Diagram & model-ling, FMEA/FMECA, Lead free – Reliability plans,Reliability demonstration plans and Life dataanalysis. Once the prototype is ready for apprais-al based reliability validation, various reliabilitytests - environmental, shock, vibration, tempera-ture cycling and life test are carried out. Reliabilityconsultants can provide consultancy on entire lifecycle of products from concept phase to mainte-nance phase.
To cite an industry example recently, when der-ating analysis was carried out on a high availabil-ity server product, it was found through detailedanalysis that a few electrolytic capacitors were notmeeting life requirement. If these were not identi-fied during the early phase of design, thousands ofproducts would have been under risk of recallafter 6 to 8 months.
Another important aspect of product quality isassessed through environmental tests. These testsare significant for ensuring quality of equipment
used in harsh environment, such as telecommu-nication equipment. This equipment needs toendure installations in harsh weather and externalconditions with fluctuations in temperature,humidity and altitude. This requires them to betested in Thermal and Altitude chambers in a lab.
Similarly, HALT or Highly Accelerated LifeTesting resulting from Design study and bug iden-tification can help bring out high quality productsand reduce product recalls. Recently, an IndianCFL (Compact Fluorescent Lamp) manufacturersaw field returns of its CFLs in large numbers. Thiswas diagnosed as a design problem by testing labconsultants after a study phase. Consultants thenput the product through Highly Accelerated LifeTesting after a design review. Reliability of CFLimproved 4 times due to increase in design mar-gin in temperature withstanding capability.Wipro’s Tarang, which houses India’s first HALTchamber, is equipped to conduct reliability test-ing of products. It can simulate harsh environmen-tal conditions with temperature ranging from+200 deg C to -100 deg C (with ramp rate of 60deg/min) along with maximum vibration level of50 Grms.
Design for safety reduces the design cycle timeby eliminating probable design issues before theproduct undergoes safety compliance test.Compliance test for safety to meet global productmarking requirement (example UL, CSA etc.) ismandatory before a product is sold in that coun-try. Design for safety review mitigates possiblefailure due to shock, fire, radiation, energy,mechanical hazard and provides appropriatesolutions to enable the product to meet standardrequirement like UL/EN 60950, 60601, 61010,60065 etc.
Safety consultancy also includes providingguidance for component selection to meet UL,CSA TUV/VDE Standards and approvals. To citean industry example - a particular product of aglobal Consumer Electronics organization offeringintegrated multimedia solutions was evaluatedand it was found that the system was restarting atextreme voltage points. Consultants reviewed thedesign schematic to suggest alternative compo-nents in regulating circuitry and implemented thesame. This led to shortening of time to market forthe customer.
One of the important aspects of testing be itEMI, Safety or Reliability is the need forLaboratory Accreditation to ISO 17025. Tarang isaccredited for ISO 17025 by NABL (NationalAccreditation Board for Testing and CalibrationLaboratories, Government of India), the accredita-tion body in India under APLAC (Asia PacificLaboratory Accreditation Cooperation) which issignatory to ILAC MRA (International LaboratoryAccreditation Cooperation - Mutual RecognitionArrangement).�
www.wipro.com www.wiprocorporate.com.
27QMT September 09
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Micro- and nano-scale structures areincreasingly playing an exciting part inthe manufacturing industries. An exam-
ple is self-cleaning glass, now widely available,which features a micro pattern engineered ontothe surface giving the window enhanced proper-ties. Micro structured surfaces are also used toimprove tribological properties in orthopaedics,leading to improved longevity of the implant. Thistrend is sure to increase and, just as standardsplayed a significant role in the advancement oftrade and prosperity in the macro world, the sameis true of the micro and nano world. With thesebenefits, substantial funding is entering these sec-tors across the globe and commercial applicationsare becoming increasingly widespread.
A micro standards infrastructure is essential toallow manufacturers to interchange parts, packag-ing and designs. Such an infrastructure will alsohelp to reduce costs, predict component compat-ibility and improve quality. This can lead to a sig-nificant time saving as developing in house stan-dards can be costly for the manufacturer and theirsupply chain. The costs of developing such stan-
dards are significant, but the rewards of doing socan be vast; not least due to the increased cus-tomer confidence when buying something speci-fied to an internationally recognised traceablestandard.
Similarly, if interchangeability of parts is tobecome a reality then manufacturers need tomove away from ‘in-house’ standards and move
towards measurement standards that are traceableto national or international realisations of the unitof length, the metre. A vital step towards this willbe widespread access to equipment that willallow manufacturers to work to these standards.
Recognising the need to overcome these barri-ers, the UK Government established the Centre ofExcellence in Metrology for Micro and NanoTechnologies (CEMMNT*), now funded by the
28 QMT September 09www.qmtmag.com
The development of a micro standards infrastructure is a critical for manufac-turers to interchange parts, packaging and designs. By Richard Leach,
Engineering Measurement Division, National Physical Laboratory.
The co-ordinate measurementmachine (CMM) revolution has yet to
come to the nano-manufacturing area
Metrology for nanotechnology
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www.qmtmag.com
Technology Strategy Board. The National Physical Laboratory (NPL), in part-
nership with CEMMNT is addressing two majorchallenges of industry. Firstly, offering openaccess to a suit of nanometrology instrumentsincluding a micro CMM, vibrometers, surface pro-filometers, and white light interferometersamongst others. Secondly, developing traceablestandards in nanometrology and offering openaccess measurement and characterisation servicesto organisations that are commercialising newmicro and nano products.
With the support of CEMMNT funding, NPL isdeveloping traceable methods to measure thedimensions of micro and nanostructures, whichbuilds on a number of instruments previouslydeveloped at NPL. Two important aspects of engi-neering nanometrology are surface topographyand micro co-ordinate metrology, and NPL isworking in these areas to provide industry with anaccurate, traceable measurement service. Thework that is being done in each of these areas isoutlined below.
Surface topography Quantitative surface topography measurement isimportant in almost all areas of manufacturing, yetthere has only been limited standardisation ofsuch measurements at the nano-scale. 3D meas-urement currently has no infrastructure, andwhilst standardisation of stylus instruments is nowunderway for 3D surface texture, there has beenvery little attention paid to the correspondingissues for optical instruments.
The topographic properties of a surface canstrongly influence its functionality and these prop-erties must be taken into account when designingor manufacturing nano-devices. Structured sur-faces are not properly represented by 2D descrip-tions; 3D measurement is a minimum require-ment.
To address these problems, NPL has developeda traceable 3D measuring instrument with a work-ing range of 8 mm x 8 mm x 0.1 mm and corre-sponding measurement uncertainties of 50 nm x50 nm x 5 nm, at a confidence level of 95 %. Theinstrument uses laser interferometers to measurethe position of a stylus in three axes and obtainstraceability to the metre via the laser sources. Theinstrument is currently being tested, with a view tolaunching an areal surface topography measure-ment service at NPL, in the near future.
To help companies develop their own traceablenano-metrology capabilities, NPL has also devel-oped areal transfer artefacts that can be measuredusing the NPL areal instrument and then used tocalibrate stylus and optical instruments in industryand academia.
Micro co-ordinate metrologyThe co-ordinate measurement machine (CMM)revolution has yet to come to the nano-manufac-
turing area. The shape of key components, fea-tures on these components and assemblies ofnano-components will need to be measured inthree-dimensions. The development of probes andprobing systems capable of making accurate, 3Dmeasurements will, therefore, be of vital impor-tance.
In recognition of the need for such measure-ments to enhance product quality and manufac-turing process control, NPL is developing a highaccuracy 3D micro-probing system capable ofincorporation into commercial micro-CMMs.
With CEMMNT funding, NPL has purchased aZeiss F25 micro-CMM and is carrying outresearch to develop a micro-probe system capableof making 3D measurements on miniature com-ponents with high aspect ratio features.
The probe element will consist of a flexurestructure with integrated sensing and actuatingelements, supporting a ball ended probe stylus. Toovercome potential problems with surface adhe-sion that can restrict the performance of smallcontact probes, the new micro-probe will bedesigned to vibrate.
The final product will be available for industryto help meet the nano-measurement challenges itfaces.
ParticipationManufacturers hoping to be part of the nano-rev-olution need to support and be involved in thedevelopment of traceable measurement stan-dards. NPL is currently looking for companieswith nano-measurement challenges that we canhelp solve. This will assist us in identifying theissues facing industry and develop standardstraceable to the international realisation of themetre, in this exciting emerging sector.Specifically, NPL is now soliciting case studiesthat will require no direct funding for NPL fromthe companies involved.
Nanometrology sets a number of challenges forthe future, but looks set to become huge business.It is, therefore, important to get the measurementinfrastructure right from the start. NPL is active inthis area and our work will help to build andmaintain the infrastructure required for commer-cial development of nanotechnology, and the pre-dicted revolution in manufacturing and life-stylethat such technologies will bring. �
Email: [email protected]. www.npl.co.uk
*CEMMNT provides a point of access for world-leading measurement, characterisation and ana-lytical services across multiple industry sectors,enabling companies to innovate in design, opti-mise product quality and performance, reducecosts and maximise competitive advantage. Itspartners are NPL, BAE Systems, QinetiQ, TaylorHobson and Coventor.
www.cemmnt.co.uk
29QMT September 09
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The imminent release of ISO 6892-1 : 2009signifies a new level of testing machine con-trol intended to improve the reproducibility
of test results obtained from a tensile test on metal.This new specification focuses particularly onclosed loop strain control of the testing machinewhilst recording data for results in the elastic andelastic-plastic transition zones. This affects resultssuch as proof stress (e.g. Rp0.2), also known asoffset yield, and Upper yield (ReH).
The accuracy of the determination of ReH, andRp0.2 has a direct bearing on the calculationsused by structural engineers involved in the build-ing industry or engineers working in collaborationwith testing institutes.
Until now variables such as different specimengrip types, testing machine load frame compli-ance, response of drive system, control electronicsand specimen stiffness contributed to differencesin results between different testing machines, andinter-laboratory tests around the world. Closedloop strain control is now internationally agreedto be the better type of machine control to obtainresults with a high level of confidence.
The closed loop strain control system of a test-ing machine is complex and requires synergy
between all major system components and insome cases the skill of the machine operator. Itrequires the testing system to monitor the strainsignal which comes from the extensometer. Thisdevice measures the increase in gauge length ofthe specimen as it is subjected to load. This sig-nal is then compared to a time base, and thedrive controller constantly adjusts the speed ofthe crosshead in order to maintain the requiredstrain rate.
The new standard requires the strain rates to becontrolled to a value of ±20% , which translates to±4 m/s at strain rate of 0.025%/s, based on 80mmgauge length. All of this can now be achievedwith a few mouse clicks using Zwick’s testXpertsoftware. The benefit to users is that it will nowbe possible to obtain more reliable and repro-ducible test results especially for materials which
30 QMT September 2009
The new standard ISO 6892-1: 2009will improve the reproducibility of testresults obtained from a tensile test on metal. Closed loop strain control systems
of testing machines will deliver results with a higher degree of confidence.
Closed loop strain control is nowinternationally agreed to be the
better type of machine control
Straining to get it right
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are strain rate sensitive.The Standard explicitly states that an exten-
someter must be used to measure the specimenstrain and the resulting strain rate must be con-trolled and maintained up to and around the char-acteristic being measured. For Rp0.2 this is rela-tively straight-forward, whilst for ReH testingmachine manufacturers have had to implementcomplex algorithms which can handle the inher-ently unstable stress / strain data as the specimentransits from the elastic to plastic zone (or behav-iour). Failure to correctly recognise this transitionpoint introduces errors in ReH.
For testing machines where closed loop straincontrol is not possible the Standard allows a posi-tion controlled variant where the crosshead speedmust be pre-selected in order to achieve thedesired strain rate. However this is time-consum-ing and requires the determination of the systemstiffness and specimen stiffness at the characteris-tic point to be measured. As a result it requires anumber of pre-tests and additional specimens inorder to set up the machine control parameters.
The following topics are also prerequisites forcarrying out tests correctly to the new ISO stan-dard:
Drive UnitThe testing machine drive units must have a highresolution positioning technology so that smalldisplacements can be traversed slowly and
smoothly. To achieve this requires high resolutioncontrol and AC motors without gears and brushes,offering the additional benefit of being wear-free,and avoiding commutation effects or torque rippleat very low speeds. The wide speed range of ACmotors, typically achieving crosshead speeds from0.01 m up to 2000mm/min or more, also allowshigh speed crosshead return or high speeds forother tests carried out on the same machine.
Compared to older technology systems, the per-formance of the latest technology enables materi-als testing machines to cycle continuously at max-imum speed over the full load range of the testingmachine without overheating.
ControllerAs mentioned earlier in this article, closed loopcontrol requires perfect synergy between all com-ponents of the testing machine, and the controlleris no exception as it forms the important linkbetween the mechanical components of the testframe and the control software algorithms.Zwick’s testControl system is able to handle mul-tiple data acquisition channels as well as controlmultiple drive units, for example when adding tor-sion applications to an normal test machine. Itsonboard firmware simultaneously handles com-plex real-time tasks, such as strain control, syn-chronized data acquisition and the monitoring ofall safety systems.
Application software The requirements of the upcoming Standard arealready totally integrated into Zwick’s testXpert IIsoftware. Easily activated, if required, it meansthat users can switch to the new algorithm as soonas the Standard is released. Operators with alter-native specifications can use the many other con-trol functions built into the system, for exampleposition control, or load / stress control. Onceconfigured for the spectrum of specimen to betested, there is no need for the operator to makepreselections as the software automaticallysearches for the appropriate test material charac-teristic, slope of elastic part, Proof Stress, or YieldStress, and controls the machine accordingly untilthe desired result has been achieved. After thatthe speed is automatically switched to that speci-fied in the next test phase of the test. The softwarehas been developed for use with Zwick’s roboTesttesting systems as these robotic testing systemsmust be able to make real-time decisions during atesting sequence. The adaptive controller adjuststhe response of the drive system according to therequired strain rate setting, specimen geometry,and load frame compliance. The testXpert II soft-ware also includes the international TENSTANDalgorithm validation system.
ExtensometersDuring the last twenty five years most organiza-tions carrying out tensile tests on metals use digi-
31QMT September 2009 www.qmtmag.com
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tal extensometers which can measure both elasticand plastics strain up to specimen failure. Thethousands of these devices in the market allow forgauge lengths from 10 to 200mm, and with high
accuracy and measurement resolutions of up to0.12 m, achieve Class 0.5 according to ISO 9513or ASTM E 83 class B-1. The benefit of thesedevices is that no operator involvement is neces-sary and this improves the reproducibility of testresults. With the advent of the new Standardthese extensometers facilitate better strain controldue to better and more consistent alignment aswell as their measurement precision. An addition-al benefit is that time is also saved whichimproves the test throughput.
Specimen Gripping SystemsThe recommended gripping solution for metalstesting using closed loop strain control is to useparallel acting hydraulic grips. The benefitsinclude: high clamping forces at the start of thetest, no slip-stick effects as with poorly maintainedwedge grips, and good specimen clamping andalignment throughout the entire test.
In summary, Zwick believes that its presence onthe International Standard Committee enables it toremain ahead of the market, and that it is the firstmaterials testing producer to integrate the require-ments of ISO 6892-1:2009 into its products. Itoffers its customers the opportunity to lead in theirown market sectors and begin working to the newstandard as soon as it is released.�
Email: [email protected] www.zwick.com
32 QMT September 2009www.qmtmag.com
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www.qmtmag.comQMT September 2009 33
The most advancedspace simulation cham-ber in the SouthernHemisphere Spanish company, Telsta, hasdesigned and developed themost advanced space simula-tion chamber in the SouthernHemisphere. This chamber willenable trials of complete satel-lites to be carried out on earthunder thermal and vacuumconditions equivalent to thosethat the satellite will experienceonce it is in orbit around theEarth.
The project has been carriedout under the direction of INPE(Instituto Nacional dePesquisas Espaciais) spaceresearch centre, which is underthe administration of theMinistry of Science andTechnology in Brazil.
The test facility will enablesimulation of the extreme tem-peratures experienced in spacein order to test the operationof the various subsystems ofthe satellite as well as the pos-sible degradation of the mate-
rials in the environment ofspace.
The space simulation cham-ber that Telstar has built forINPE is in the shape of a tun-nel or a ’mailbox‘ with internalmeasurements of 7m in width,8.5m in height and 9m indepth with a total internal vol-ume of 485 m3. Its main
functional characteristics arean ultimate vacuum level of1x10-7 mbar and the temper-ature control range from -180ºC to +150ºC workingwith nitrogen gas in the ther-mal panels (shrouds), or downto -196ºC when flooding theshrouds with liquid nitrogen.The test facility data acquisi-
tion system has 1500 channelsfor the recording and analysisof the experimental data.
By controlling different tem-perature settings in each of the6 zones of the thermal shroudin the chamber, an environ-ment that simulates the condi-tions of temperature foundwhen the satellite is manoeu-vering in orbit around theEarth can be created, provid-ing the engineers and design-ers with vital information of thebehaviour and functionality ofthe satellite before launch.
In space, far away from theterrestrial surface, the pressureis around 1x10-13 mbar andthe temperature to which thesatellite will be submitted(depending whether or not it isreceiving direct solar radiation)can vary between 650K(377ºC) and 4K (-269ºC).The simulator developed byTelstar reaches vacuum valuesof the order of 1x10-7mbarand temperatures of -196ºCto +150ºC, far beyond thanthe majority of conventionalsystems.
www.telstar-vacuum.com
Struers LtdUnit 25a Monkspath Business Park, Solihull B90 4NZTel: 0121 745 8200 Fax: 0121 733 6450 E-mail: [email protected]
Excellence in Non Destructive Testing
With a 130 year pedigree and a reputation for providing materialographic solutions, it’s not hard to see why more and more NDT professionals team with Struers. They need the same level of innovation and relaibility
They need to get the job done. They need to get the job done well. Talk to Struers about the Struers range of NDT equipment including mechanical and electrolytic preparation and on-site replication and inspection.
See us at Materials Testing 2009, 15-17 September, Norbreck Castle Hotel, Blackpool
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Materials Testing 2009 is the most compre-hensive international exhibition in test-ing for quality, materials testing, non-
destructive testing, condition monitoring anddiagnostic engineering. Organised by the BritishInstitute of Non Destructive Testing, BINDT,Materials Testing 2009 will be held 15-17thSeptember at the Norbreck Castle Hotel andConference Centre, Blackpool, United Kingdom,which was recently refurbished at a cost of £10million
Running alongside the Materials TestingExhibition is the Institute’s Annual Conference,NDT 2009, allowing delegates many opportuni-ties to visit the show. The conference programmehas three parallel sessions covering a wide rangeof advances in NDT over many fields of applica-tion, from crack detection and condition monitor-ing to eletromagnetics, phased arrays and thermalNDT to mention a few. The full conference pro-gramme is available on BINDT’s website,
www.bindt.or
New products at MT2009Advanced NDT Ltd is using the BINDT Materials
Testing 2009 Exhibition to launch the new Isonic2009 Phased Array Ultrasonic Flaw Detector.Concerned that some simple phased array unitsare being misused, Sonotron, the instrument man-ufacturer, have developed the Isonic 2009 toeliminate some of current errors.
A major advantage of Phased Array units is theability to sweep the beam angle to cover a greatervolume of material in one pass. Unfortunately,simpler instruments do not compensate for thegain changes at different refractive angles anddefects could be missed.
The Isonic 2009 compensates for the refraction,
34 QMT September 2009
Materials Testing 2009, in Blackpool, is the the industry's premier eventfor NDT technology with a comprehensive exhibition and conference
organised by the British Institute of NDT.
Materials Testing 2009
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wedge attenuation and so on, to give a uniformsensitivity over the inspection area. The materialthickness may be entered to display the skippedbeam path for angle beam inspections and weldprofiles added, making defect positioning andinterpretation easier.
www.advanced-ndt.co.uk
Corrosion Wheelprobe launchSonatest, stand 72, are launching the CorrosionWheelprobe for pipeline corrosion mappingapplications. Ergonomically designed, theCorrosion Wheel Probe offers smooth handling,good control and comfortable grip positions forscanning around pipes and for easy overheadwork. The Corrosion WheelProbe needs littlesupport for use in the field, the Array angle is
adjustable in situ, requiring no tools, whilst drybearings enable angle rotation.
Circumferential and Longitudinal scanning areboth completed rapidly and can be performed onpipes with diameters between 3 and 32 inches.Fast and easy configuration for different pipediameters is possible in the field thanks to thePipe Diameter Scale on the instrument itselfwhich enables quick adjustments and fine tun-ing.
www.sonatest.com
UV light sourceUltrafine is a manufacturer and supplier of endo-scopes and video systems for remote visualinspection and of UV light sources and liquid lightguides for crack detection and other fluorescenceinvestigations. On show is a new battery operatedversion of its Lumatec UV light source (photo left). together with fibrescopes, videoscopes andvideo workstations.
www.ultrafinetechnology.com
NDT instrument rental Instrumentation specialists Ashtead Technologywill be demonstrating the latest in Non-Destructive Testing (NDT) equipment at this year’sMaterials Testing Exhibition. The company willalso be explaining the benefits of hiring over buy-ing outright at the event .
35QMT September 2009
MT 2009 Exhibitor stand numbers
1 High Technology Sources Ltd 2 High Technology Sources Ltd 4 TWI Training & Examination Services 6 TWI Ltd, NDT Dept 8 Lemo UK 10 The Validation Centre (TVC) Ltd 12 Mercury Computer Systems14 Ashtead Technology16 Ashtead Technology18 NDT Maincal Ltd20 Argyll-Ruane Ltd 22 Prüftechnik Ltd 24 Hirox Europe 26 Zetec Inc 28 Advanced NDT Ltd 30 Struers Ltd 32 Gilligan Engineering Services Ltd34 Physical Acoustics Ltd 36 Chemetall Ltd 38 AGR Field Operations 40 Aegleteq Ltd 42 Silverwing (UK) Ltd 44 Johnson & Allen Ltd 46 Inspection Software Ltd48 Vidisco Ltd 50 GE Inspection Technologies 52 Olympus Industrial54 Fujifilm UK Ltd 56 Fujifilm UK Ltd 58 Midas NDT Systems Ltd60 Wardray Premise Ltd62 NDT Solutions 64 NDT Solutions 66 Karl Storz GmbH 68 CIT Ltd 70 RSL NDT Ltd 72 Sonatest Ltd74 Testrade Ltd76 Lavender International78 Diagnostic Sonar Ltd82 TSC Inspection Systems 84 VMI UK Ltd86 TSC Inspection Systems 88 Global School of NDT/Ameritest LLC
90 Phoenix Inspection Systems 94 Phoenix Inspection Systems 96 CEDRAT 98 JFIMS 102 Rohmann UK 104 Technical Solutions 24 Seven Ltd 106 RWE Npower108 TEST NDT International 110 JME Ltd 112 Ultrafine Technology Ltd 114 Sonaxis 116 CEMMENT 118 National Physical Laboratory
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Instrumentation shown on the Ashtead stand(14/16) will include the Niton XRF metalsanalyser, the advanced FLIR P620 ThermaCAM,the Olympus I-Speed (high speed) camera and theGE Inspection XL GP videoprobe.
Ashtead’s General Manager James Carlyle said:“We will have expert staff on our stand through-out the event to provide information and adviceon which instrument best suits individual needs.”
Email [email protected]
Exhibitor case study - PhoenixInspection SystemsA scanner to test the integrity of storage tanks hasbeen produced by Phoenix Inspection Systems.The system was commissioned by DoosanBabcock on behalf of Babcock Marine at theRosyth Naval Dockyard in Fife, Scotland, and has
been designed to carry out inspection of the wallsof a set of storage tanks as part of a programme ofintegrity assessment.
The two-axis automated system consists of a lin-ear and turntable drive carrying ultrasonic trans-ducers located on the end of a pneumatic operat-ed arm that is also equipped with a camera forvisual inspection. It uses 0° probes to measure thethickness of the tank walls and angled beamprobes to inspect critical weld areas for internaldefects and cracks.
Dr Neil Hankinson, project manager atPhoenix, said: “This particular system wasdesigned to operate in a harsh environment andcarry out detailed scans of the tank wall from theinternal surface. The requirements were to fitthrough a small access hole and to scan the com-plete surface whilst negotiating a number of inter-nal obstructions, such as stiffening bars and inlet /outlet nozzles, that hinder access and motionwithin the storage tanks.
“Inspecting these tanks to check their conditionis a far more economical option than replacingthem at regular intervals since design estimates onthe tank’s life expectancy are often extremely con-servative. The inspection system provided willallow Babcock Marine to maintain its high safetystandards whilst reducing the frequency of replac-ing their storage tanks.”
www phoenixisl.co.uk
36 QMT September 2009www.qmtmag.com
TESTING SUPPLEMENTTESTING SUPPLEMENT
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www.qmtmag.comQMT September 09 37
General purpose thick-ness gaugeThe Cygnus 4 GeneralPurpose Multiple Echo thick-ness gauge, from CygnusInstruments, has been engi-neered to be the smallest,lightest yet toughest instru-ment of its type.
The Cygnus 4 has a 3-button keypad and user-friendly menu and featuresautomatic probe recognition(APR) for perfectprobe/instrument optimisa-tion, minimum thicknessalert, echo strength indica-tion, display freeze and‘Deep Coat’ mode to allowmeasuring through eventhicker coatings up to 20mm thick. The large LCDgraphic display has a fullyautomatic, white back lightfor all light conditions, with
the velocity of sound, probetype and battery statusalways displayed. Suppliedin an IP65 and IP67 ratedaluminium enclosure thegauge can function perfectlyin the most difficult operat-ing environments.
www.cygnus-instruments.comEmail: sales@cygnus-instru-
ments.com
First industrial CT sys-tem with unipolar300 kV microfocus X-raytubeGE Sensing & InspectionTechnologies is adding thev|tome|x L 300 to itsphoenix|x-ray range. This, sayGE, is the first computedtomography (CT) system whichcan achieve a resolution of1μm with a 300kV X-ray tubewhile offering higher contrast
resolution through a tempera-ture-stabilised GE digitaldetector. The CT system isequally suited to 2D and 3Danalysis as well as to the pre-cise dimensional measurementof components, which, owingto their complex structure, can-not be inspected in a non-destructive manner using opti-cal or tactile coordinate meas-uring machines. As such, it willfind particular application inthe automotive and aerospacesectors, as well as the engi-neering sector in general.
The newly developed 300 kV/ 500 watt microfocus X-raytube of the v|tome|x L 300 issuitable for high magnificationapplications as well as scansof strongly absorbing samplesand is ideal for quality moni-toring. For example, it cancapture cast parts weighing upto 50 kg in three dimensionsat high resolutions and createvirtual cross-sections of thepart’s interior from any angle.The system also has a specialmetrology package that con-tains everything needed fordimensional measuring withthe greatest possible precisionand user-friendliness, fromcalibration instruments to sur-face extraction modules. Inaddition to 2D wall thicknessmeasurements, the CT volumedata can be quickly and easilycompared with CAD data, forexample, in order to analysethe complete component toensure it complies with allspecified dimensions.
Whereas the bipolar con-struction and comparativelylarge focal spot of convention-al 300 kV X-ray tubes do notpermit high geometric magni-fication, the new phoenix|x-rayX-ray tube is unipolar, with afocal spot only 4.5 mm fromthe X-ray beam. As cone-beam
tomography only allows partic-ularly high magnifications witha very short focal point toobject distance, the unipolar300 kV tube definitely has theadvantage. The v|tome|x L300 also has a measuringrange extension for samplesup to 500 mm diameter. Tofurther improve the quality ofthe scan, the system can beequipped with a multilinedetector. To avoid installing anexchangeable head, thev|tome|x L 300 can also befitted with an additional 180kV high-power nanofocus X-ray tube for particularly highresolution scans. The tubescan simply be changed at thepress of a button.
www.geinspectiontechnolo-gies.com
Micro focus CT for crys-tal clear inspection ofturbine blades anddense parts Metris has introduced a high-powered, 450kV micro-focusX-ray/CT system for full insightinspection of turbine blades,castings and other dense
objects. Its 450kV micro-focussource combined with thenewly developed CurvedLinear Array (CLA) detectormaximizes the detection of X-ray flux resulting in 25 micronaccuracy and repeatability.Through automated inspectionand high-speed CT reconstruc-tion, blade manufacturers rundetailed CT inspection of light-weight turbine blades to opti-mize the fuel economy of jetengines, contributing to agreener environment.
At the core is a450kV/1200W micro-focussource, delivering focal spotsize up to 25 micron! As thismicro-focus spot size is consid-erably smaller than existingmini-focus sources, the level ofdetail that it captures isbeyond comparison, claimMetris..The proprietary 450kVsource offers sufficient X-raypower to penetrate densespecimens, such as turbineblades and caste engine parts.
To meet stricter toleranceson inner and outer wall thick-nesses for latest- generation jetengine blades operating inextremely high temperatures,micro-focus X-ray and CTinspection is the solution.Single-crystal metal alloy tur-bine blades designed for opti-mum aerodynamics and masscentre location, resist highertemperatures and avoid corro-sion. Superior blade character-istics contribute to higher effi-ciencies in aircraft jet enginesor in power plants, reducingfuel consumption and the dis-charge of greenhouse gases.
www.metris.com
NDT & NDI
QMT_Sep09.pdf_1 24/8/09 14:00 Page 37
PRODUCTS
www.qmtmag.com QMT September 200938
Test or monitor virtuallyanythingsigPOD PSV, from SciemetricInstrument, is an out of thebox, user configurable solutionthat can be used to test ormonitor virtually any operationduring manufacturing, includ-ing press, torque, vibration,dispense, and functional test.An easy to use, intuitive set upinterface makes it easy toleverage the expansive libraryof processing and analysistools available, and can beused on up to 8 channels toallow for greater output with-out sacrificing quality.
www.sciemetric.com.
Portable GC leak detec-tor is quick & preciseThe Thermo Scientific GLDPRO Leak Detector can identifygas leaks precisely and quick-ly. This ergonomicallydesigned, hand-held electronicdevice is a highly sensitiveinstrument for use with gaschromatography (GC) systemsand their accessories, such aspurge and trap systems. Thiscompact unit provides fast,
contamination-free, leakdetection, and offers a muchmore reliable and convenientmethod than liquid leak detec-tors, which can contaminatethe column and cause perma-
nent damage to the stationaryphase. It is capable of detect-ing even the smallest gas leaks(<1 ml/min), and any leaksare indicated with both a LEDlight display and an audiblealarm. Therefore, the ThermoScientific GLD PRO LeakDetector is ideal for checkingvalves, fittings, and traps forleaks after maintenance, pre-venting damage to columnsand sensitive detectors,improving analytical perform-ance and minimizing trou-bleshooting.
www.thermo.com/columns.
Force measurementmodules The new RG smart load cellfrom Mark-10 is a plug-and-play force measurement build-ing block designed for integra-tion within assembly systems,weighing systems, and otherprocess automation and test-ing automation applications.
All functions are controlledby commands sent from a PCor PLC via its RS-232 connec-
tor. The RG's ASCII commandlibrary allows for peak forcerecall, set points, data averag-ing, data filtering, calibration,and many other functions.
A rugged aluminum hous-ing makes the RG durableenough to withstand therigours of manufacturingenvironments. Capacities areavailable from 2 lb to 200 lb(10 N to 1000 N).
www.mark-10.comEmail: [email protected]
Automated test systempunches holes inplasterboardA specially adapted force test-ing system from Mecmesin isbeing used to measure thequality of gypsum plasterboardproducts.
The system was purchased
by Saint Gobain, leaders inthe design, production anddistribution of materials for theconstruction, industrial andconsumer markets. Theywished to accurately assesstheir plasterboard productsperformance and durability.
Mecmesin offered a speciallymodified MultiTest 1-x console-controlled test system, capableof testing up to 1kN. This is
used in combination with asimulated PLC (ProgrammableLogic Controller) indexing unit,which enables full automationof the test method. When con-nected to the MultiTest-x, thesimulated PLC indexing unitperforms a pre-programmedtesting sequence by runningthe operations that are nor-mally undertaken manuallyduring tests.
The application requires aprecision probe to be fittedonto the systems loadcell, withthe plasterboard fixed to amoveable platform. The probeis inserted into the side struc-ture of the plasterboard to adepth of 13mm. Once com-plete, the simulated PLC index-ing unit signals the platform tomove enabling the same testto be performed on a new sec-tion of plasterboard. Up to 50tests can be undertakensequentially without the needfor an operator to activatecontrols, thereby saving thetime and labour normally
required for this type ofassessment.
Email: [email protected]
Pipe girth welds areright first time The Internal Weld ScanningTool, developed by UK-basedcompany Optical MetrologyServices (OMS), internallyscans welds inside pipes –both visually and dimensional-ly – enabling engineers toquickly and confidently assessthe quality of the root weld.
The technology can bedeployed onshore and off-shore at different stages of thepipe welding process. The toolcan be used on corrosion-resistant alloy-lined pipe toidentify sour (aggressive)ingress points, in both cladbutt-weld and clad weld inlayapplications. The tool can alsobe used to improve weld pro-cedure development efficiencyand to check the root weldand geometry before nextpasses are deposited. Thetechnology provides similaruses in fatigue-sensitive appli-cations (SCRs) where the pipeis subject to higher dynamicstresses.
The system can be mountedto a purge dam, with an inte-grated camera for positioningand inspection. Pipe can beinspected whilst it is beingspooled onto a pipe layingvessel or during stalk fabrica-tion/tie-in. Here, the tool isretrieved using a winch andwire system, with weld posi-tioning controlled by a cameraand precision motorised sys-tem.
Email [email protected]
www.optical-metrology-serv-ices.com
TESTING SUPPLEMENT
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PRODUCTS
www.qmtmag.comQMT September 2009 39
Foundation degree inmetrology launchedCoventry University is tobecome the first institution inthe UK to offer a qualificationin metrology - the science ofmeasurement - helping to fillan important skills gap in thecountry. The first students willbegin the course this August.
The foundation degree hasbeen developed by the Schoolof Lifelong Learning atCoventry University, with sup-port from the National PhysicalLaboratory (NPL), the UK’snational measurement insti-tute. The course is aligned toNPL’s training framework,meaning that graduating stu-dents will receive the dualaccolade of the degree itselfand certification from NPL.
The qualification fills thespecific skills gap in the under-standing and application ofmeasurement; allowing organ-isations to benefit from savingsin both time and moneythrough the implementation ofbest practice within metrology.
Trevor Toman, MetrologyManager for the WestMidlands ManufacturingMeasurement Centre(WMMMC) explains: “TheFoundation Degree inMetrology sets out to satisfythe needs of manufacturing,the individuals within industryand the scientific world. Westrongly believe that metrologyeducation should be diverseenough to satisfy the personalrequirements of the metrologygeneralist and the metrologyspecialist, also that it shouldsatisfy industrial needs nowand in the future; that it shouldcover the laboratory and theshop floor and finally that itshould prepare researchers forfurther study. This course isabout applied measurement inreal situations for improvedperformance.”
Fiona Auty, Head ofCommunications and Trainingat NPL, who has been helpingto develop the course, com-mented: “With many talentedgraduates struggling to findwork, it is reassuring that newcourses are being developedthat offer high academic stan-dards, whilst also addressingpredicted gaps within impor-
tant areas of industry and pro-viding students with the skillsthey need to find a career”.
This new Foundation Degreeis a key step towards metrolo-gy gaining recognition as aNational OccupationalStandard (NOS). There is cur-rently no standard describingthe precise role of metrologypractitioners, despite thou-sands of UK employees work-ing in the field.
www.npl.co.uk
Pioneer Lean trainingManufacturing companiesacross the UK will soon bebenefiting from a unique train-
ing programme developed inthe South West.The National Skills Academyfor Manufacturing (The SkillsAcademy) has been workingwith manufacturers in theregion to pilot new coursesthat promote ‘Lean’ manufac-turing processes.
Brian Thornton, regionalmanager for The SkillsAcademy in the South West,explained: “Over the past fewmonths we have been workingwith two companies in theregion to trial the LeanFoundation Programme, anentry level short course thatgives workers an introductionto the principles of lean manu-
facturing.”The two companies –
Plymouth-based computer cabi-net manufacturer Rittal-CSMand Relyon, which makes bedsat its factories in Wellington,Taunton and Okehampton –have introduced the coursealongside NVQ qualifications inBusiness ImprovementTechniques. As a result theyhave seen marked improve-ments in quality, cost reductionand product delivery. The initialpilots have proved so successfulthat the course look set to beadopted across the UK.
Email: [email protected]
www.nsa-m.co.uk
Micro & Nanotechnology Measurement Services
The National Physical Laboratory is a world-leading centre for the provision of micro and nanotechnology measurement services and solutions. NPL also develops measurement related standards, technology and provides best practice. NPL makes its science and technology as valuable, relevant and accessible as possible to our customers.
Please visit the Products and Servicessection at www.npl.co.uk to learn moreabout micro and nanotechnology measurement services offered by NPL.
NPL is a partner with CEMMNT(Centre of Excellence in Metrologyfor Micro and Nano Technologies) inproviding world-leading measurement,characterisation and analytical servicesacross all industry sectors.
TRAINING & EDUCATION
QMT_Sep09.pdf_1 24/8/09 14:00 Page 39
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